Month: August 2025

Describe

This manual introduces the hardware related content of the Woodward 723PLUS digital controller (models 9906-619, 9906-620, 9906-700), including general information, installation, control setpoint input, use of Servlink and Watch Window, product support and service options, etc. The controller is suitable for various application scenarios that require speed control.

General information

Application scenarios: It can adapt to various applications through programming. The hardware includes two speed inputs, supports two magneto electric sensors (MPUs) or proximity switches (such as for torsional filtering), as well as four analog inputs, three analog outputs, eight discrete inputs, and three discrete outputs, which can be used in load sharing systems. Its two LON channels can support related control functions.

Control options: Different models have different power input voltage requirements, and discrete input voltage provides switch command signals for control. There are also various other control options, such as proximity switch input suitable for low-frequency speed signals, 0-1mA output of instrument drivers, etc. The controller can be used in conjunction with proximity switches or magneto electric sensors with minimum frequency requirements.

Attachments: including handheld programmer (9907-205), SPM-A synchronizer, power output sensor, active power sensor, etc.

install

Scope: This includes general installation instructions for the 723PLUS controller, including power requirements, environmental precautions, location considerations, as well as unboxing, electrical connections, and installation inspection procedures.

Unpacking: Before handling the controller, it is necessary to read the relevant content on electrostatic discharge protection. When unpacking, be careful and check whether the controller is damaged. If there is any damage, immediately notify the shipper.

Power requirements: High voltage models require a 90-150Vdc voltage source, while low voltage models require an 18-40Vdc voltage source. To prevent damage to the controller, the input voltage range must not be exceeded. If battery power is used, an AC generator or other battery charging equipment must be equipped.

Location considerations: When selecting the installation location, factors such as ventilation, maintenance space, liquid and condensation prevention, electromagnetic interference prevention, and vibration prevention should be taken into account. The controller should not be installed on the prime mover, and the operating temperature range is -40 to+70 ° C (-40 to+158 ° F).

Specific installation requirements for marine use: The certification requirements for marine use types may change over time. In order to meet these requirements, all wiring, except for the part near the control connection terminal, must be inside metal conduits, and the control must be installed on a grounded metal mounting plate. It is also possible to meet attenuation requirements at specific installation locations or methods without additional special measures, but consultation with the shipyard is required.

Internal jumpers: The 723PLUS controller has ten two position internal jumpers located at the top of the printed circuit board. If you need to change the jumpers, you need to read the electrostatic discharge protection content first, power off and wait before operating. Different jumpers have different default settings and functions.

Electrical connection: External wiring connection and shielding requirements should refer to relevant software manuals. All shielded cables must be twisted pair, signal lines should be shielded, and shielding layer connections should follow specific requirements. It also provides detailed instructions on the connection methods and precautions for power supply, analog output, actuator output, speed signal input, load sharing line input, discrete input, analog input, etc.

Installation inspection program: After installation, visual inspection (checking linkage devices, wiring, terminals, speed sensors, etc.) and grounding inspection are required to ensure that the resistance between each terminal of the controller and the chassis meets the requirements.

Serial port communication: The 723PLUS has two serial ports for communication, which can be configured into multiple types through software. When writing applications, it can be configured as a Modbus communication port and supports relevant protocols.

Terminal matching and grounding shielding: Different communication types (RS-422, RS-485) have different terminal matching requirements. RS-422 and RS-485 specifications require grounding wires when there are no other grounding paths between units. There are preferred and alternative wiring methods, and shielding and grounding must be handled correctly.

Control set point input

Overview: Due to differences in installation, system, and component tolerances, the 723PLUS controller must be adjusted for each system to achieve optimal performance. Setpoint inputs can be made through a handheld programmer or PC (using Watch Window software tools and Servlink software).

Handheld programmer and menu: The handheld programmer obtains power from the 723PLUS controller, connects to the RS-422 communication serial port of the controller, performs self check after power on, and displays application related information on the screen. The controller has a service menu and a configuration menu. The configuration menu needs to be entered when I/O is turned off (engine stopped), and the service menu can be directly entered through buttons. The operation menu and settings

Control set point input

Overview

Due to differences in installation environment, system, and component tolerances, the 723PLUS controller needs to be adjusted for specific systems to achieve optimal performance. Setpoint input can be completed through a handheld programmer or by connecting to a PC (using Watch Window software and Servlink software).

Handheld programmer and menu

Programmer connection and self-test

The handheld programmer (model 9907-205) obtains power from the 723PLUS controller and connects to the RS-422 communication serial port (J1 terminal) of the controller. When connecting, slightly loosen the right screw of the J1 port cover plate, rotate the cover plate clockwise to expose the 9-pin connector, and then firmly insert the programmer connector into J1.

After connecting the programmer to the controller, it will perform a power on self-test. After the self-test is completed, the screen will display two pieces of information related to the application. Press the ID key to switch between displaying the software’s part number and version letter.

Menu type and access

Configure menu: It needs to be accessed while the engine is stopped. Press the corresponding button, and the screen will display “To select configure, press enter”. After pressing the ENTER key, it will display “To shutdown I/O, press enter”. Press the ENTER key again to enter. If the engine is running during this process, it will shut down due to controller I/O shutdown.

Service menu: Press the DOWN ARROW key to access without shutting down the engine.

Menu Operation

Move between menus: Use the LEFT ARROW and RIGHT ARROW keys.

To move between set points within the menu: use the UP ARROW and DOWN ARROW keys.

Return to menu title: Press ESC key.

Exit menu: Press the ESC key, and the configuration menu will automatically save the set points when exiting.

Setpoint adjustment

Arrange mode

Use the TURTLE UP or RABBIT UP keys to increase the set value, and the TURTLE DOWN or RABBIT DOWN keys to decrease the set value. The adjustment rate of the RABBIT key is about 10 times that of the TURTLE key, which is suitable for situations where a large adjustment value is required.

For settings that require the selection of TRUE or False, use the corresponding increase or decrease keys.

Use the+or – keys to gradually change integer values in the application software.

To enter a precise value, press the=key, enter the desired value, and then press the ENTER key, but the value must be within 10% of the existing value.

Save Setpoints

At any time, the SAVE key can be used to save the set points and transfer the new set point values to the EEPROM memory, which retains all set points even when the controller is powered off.

To prevent the loss of set values after the controller is powered off due to the failure to save the set points, which may damage the engine, it is necessary to save the set points before removing the controller power supply.

Overview

This manual covers models 512/524 and 1712/1724 of Woodward EPG (Electrically Powered Governor) electric governors, including synchronous models, covering installation, operation, calibration, troubleshooting, and other content. It is suitable for speed control of diesel, gas, and gasoline engines as well as gas turbines.

General information

Application scenario: Used to control the speed of diesel, gas, gasoline engines and gas turbines, suitable for prime movers of mechanical loads and generator loads. Parallel generator sets require additional equipment and Woodward generator load sensors.

Model selection: 512/1712 models are used for 12V systems, and 524/1724 models are used for 24V systems. The speed controller has four frequency ranges for magnetic and electric sensors, suitable for different engine types. The actuator has a dual end output shaft that can rotate clockwise or counterclockwise to increase fuel consumption. You can also choose to activate functions such as fuel limit and dual dynamic characteristics, and select compatible speed controllers and actuators according to the model selection table.

Attachment: Includes generator load sensor (for parallel generator applications), ramp generator (for slowing down acceleration and deceleration), external capacitor (providing exponential ramp), etc.

Reference materials: Relevant publications can be obtained from authorized Woodward distributors or AISF, and can also be viewed on the Woodward website.

Installation, inspection, and calibration

Installation of speed controller: The working temperature range is -40 to+75 ° C (-40 to+167 ° F), and it should be installed in a location with adjustment and wiring space, avoiding exposure to radiant heat sources, close to actuators and batteries to meet wire length requirements, and ensuring good ventilation.

Installation of actuator and linkage device: The operating temperature range of the actuator is -40 to+93 ° C (-40 to+200 ° F), avoiding exposure to excessive heat sources. Suitable linkage devices need to be selected to match the rotation direction of the actuator and fuel control, ensuring that the linkage device moves flexibly, without friction or clearance. The actuator includes a reset spring, which does not require additional addition.

Installation of magneto electric sensor: Installed through the shell or rigid bracket, ensure that the detected gear is made of magnetic material, and the gap between the sensor and the outer diameter of the gear is about 1.0 millimeter (0.04 inch) at the closest point. The gap can be set in a specific way and the anti loosening nut can be tightened.

Wiring instructions: Use a specific wiring diagram for wiring, and use insulated terminals for all connections. The wiring to the actuator and battery should be as short as possible, and different models have different maximum wiring lengths. Fuses and switches or circuit breakers should be located in non grounded battery leads, and the connection between the battery and the speed controller terminal should come directly from the terminal, without passing through the distribution point. Attention should also be paid to the shielding layer connection and the installation of varistors required by EMC.

Installation inspection: including checking electrical connections, installation of magneto electric sensors, fastening of actuators and linkage devices, testing battery voltage, terminal voltage, preset rated speed and idle speed, adjusting gain and stability, setting starting fuel limits, etc. There are additional inspection steps for different application scenarios (such as applications with 2500 ramp generators and parallel generators).

Operate

The governor needs to be powered on at startup and powered off at shutdown (if the fuel control is in the minimum fuel position, power off will cause shutdown). The application of parallel generators requires synchronous and parallel operation. In droop mode, parallel operation requires adjusting the speed and fine tuning potentiometer to set the power generation. The EPG design is suitable for unmanned operation, and the idle rated switch can be controlled by multiple devices. When using the Woodward SPM synchronizer for parallel generator applications, equivalent automation operation can be achieved. The ramp generator can be used to provide adjustable speed change time between rated and idle.

Describe

Speed control application: The basic speed control components include magneto electric sensors, speed controllers, and actuators, with two control loops: speed loop and current loop. The speed loop controller compares the expected speed with the actual speed, calculates the error signal, and adjusts the gain and stability to customize the governor response; The current loop ensures the correct driving of the actuator, including relevant circuits and protection mechanisms.

Executor: The mechanical structure is simple, with specially designed rotors and stators. The rotating design enables low-quality, low friction fuel control to achieve a certain angle of shaft rotation. When the magnetic circuit is energized, it provides torque in the direction of fuel increase, and the internal reset spring provides shaft torque in the direction of fuel decrease.

Application of using a ramp generator: slows down the speed change between idle and rated speed, without affecting steady-state speed, and controls the rate of change through acceleration and deceleration potentiometers.

Parallel generator application: Load sensors are used for synchronous or droop parallel connection. When isolating the bus, synchronous load distribution is usually selected. When parallel connected with infinite bus or incompatible electric speed controllers, droop operation is required.

Troubleshooting process

When there is a problem with the operation of the prime mover, it is necessary to first determine whether the fault is caused by the governor. The following methods can be used to troubleshoot:

Component replacement: Replace suspected faulty components with known normal ones.

System simplification: Gradually remove optional components and observe the performance changes after each removal.

Component testing: Test the output of suspected faulty components according to the manufacturer’s instructions or known input and operating conditions.

When testing EPG, you can refer to the installation inspection steps in Chapter 2, where using a signal generator with isolated output for rated speed preset is the best way to test EPG speed control capability. If it involves the application of parallel generators, it is also necessary to refer to the inspection content of load sensors in the 82313 manual mentioned in Chapter 2.

Other inspection items

Unstable speed or power output

If the prime mover remains stable at certain speeds or power outputs but oscillates in other situations, it may be due to incompatibility between the linkage device and fuel control. Please refer to the “Linkage Device Compatibility” section under “Installation of actuators and linkage devices” in Chapter 2.

If there is a low-frequency oscillation of about 1Hz in the prime mover and the gain and stability adjustments in Chapter 2 are correct, it may be due to friction in the linkage device. It is necessary to disconnect the actuator from the fuel control, manually operate the fuel control linkage device, check whether it moves flexibly without friction or clearance, and lubricate or replace components if necessary.

Unstable load distribution

Verify if the current transformers (CTs) and voltage transformers (PTs) of the load sensor are wired correctly.

Check if the droop or cross current compensation settings of the voltage regulator are correct, and if there are intermittent faults or other issues with the voltage regulator.

If the problem persists, the load gain can be appropriately reduced and the load gain potentiometers of all other load sensors in the system can be set to have the same load signal at full load. In extreme cases, the load signal may need to be reduced to 3 volts. In this case, authorized dealers or Woodward can be consulted.

Fuse or circuit breaker issues

If the fuse or circuit breaker disconnects after the prime mover is running, it may be due to high voltage spikes generated by the battery or battery charger. It is necessary to separately wire from the speed controller to the battery terminal as shown at the top of Figure 2-6.

If the fuse or circuit breaker is disconnected during initial startup, it may be a battery connection error. It is necessary to verify whether the battery connection is correct, remove the wires from terminals 1 to 4, and check whether each wire is short circuited to ground.

Differences in performance between hot and cold states

If the prime mover oscillates in the cold state and stabilizes in the hot state, the gain potentiometer can be slightly rotated counterclockwise. If stability needs to be maintained, the stability potentiometer can be slightly rotated clockwise.

Overview

This manual is the second volume of the Woodward 505 turbine digital controller, mainly covering service tools, peripheral devices, application notes, operator interface, service menu program, PID setting understanding, hardware/operating system faults, and multiple appendix contents. It aims to help users understand the application, configuration, operation, and fault handling of the controller.

Service Tools

Control Assistant (CA): The main service tool that can upload and download adjustable parameters, display real-time trends of any I/O signals or control parameters, troubleshoot system issues by viewing system software variables, and analyze any data log files collected from the controller.

Servlink to OPC Server (SOS): Integrated with Control Assistant, running as a service on PC, converting Woodward proprietary Servlink data from 505 to OPC data. The Control Assistant tool will connect to the SOS server as a client, and customers who want to link from 505 to OPC data also need to connect to SOS.

AppManager (AppMan): Used to transfer files to and download files from the controller. It can set the controller’s Ethernet port IP address and SNTP time synchronization IP address for network time protocol synchronization. It can also install software service package programs, start/stop control programs, or GUI programs.

Peripheral unit

DSLC-2 (Generator Synchronizer and Load Control): Connected to the 505 controller, it can be used to accurately detect the three-phase RMS generator output power and perform generator circuit breaker synchronization. It can also configure generator load distribution, reactive power or power factor control, process control, and basic load control functions.

VariStroke II (electro-hydraulic actuator): A linear electro-hydraulic actuator designed to provide linear driving force for steam turbine control valves or valve frames, which can be directly networked with the 505 controller to reduce system complexity and wiring requirements.

MFR300 (Multi functional Relay): A multifunctional generator protection relay used to detect and protect small generators, integrating all generator protection functions into a universal device to reduce overall system installation complexity and cost.

LS-5 (Protection/Circuit Breaker Control Relay): Integrated with generator circuit breaker synchronization, power detection, and protection functions, designed to be used in conjunction with prime mover controllers such as 505 to achieve precise generator control and provide the required generator protection.

Servo Position Controller (SPC): can be used to connect the 505 digital controller with existing valve operators or Woodward actuators, suitable for action integration or situations where it is directly incompatible with the 505.

Real Power Sensor: Used to detect the active power generated by the generator or the active power flowing through the interconnection line. Woodward manufactures two types of active power sensors, one that can only detect power flow in one direction and the other that can detect power flow from the bus to the interconnection line.

Engine Generator Control Package/Load Sharing (EGCP-3 LS): Based on microprocessors, it is suitable for three-phase AC generators equipped with Woodward speed controllers and automatic voltage regulators. It integrates functions such as synchronizers, load control, dead bus closure systems, reactive power/power factor control, process control, power and energy metering, and protective relays.

Application Notes

Overview: This article introduces the capabilities of the 505 digital controller and its application in the system. By demonstrating typical steam turbine applications and explaining their functions, it provides assistance for application programmers to configure the 505. It also explains how to apply control parameters or combinations not shown in the system.

Example applications: Contains various example applications, such as pump or compressor discharge pressure control and turbine inlet pressure limitation, inlet pressure control and automatic synchronization, and generator power limitation. Each example has corresponding configuration instructions and startup and operation mode instructions.

Operator Interface

Graphic display and key input: The service panel of the controller consists of hard key command buttons, soft key command buttons, and a graphical user interface screen. The system operator communicates with the 505 system through the service panel.

Service panel mode and user level: The 505 service panel has multiple modes (operation, calibration, configuration) and user levels (monitoring, operator, service, configuration). Different user levels determine the accessible and adjustable parameters and executable operations, and specific rules must be followed when adjusting values.

Service menu program

Overview: The service menu format of the 505 controller is easy to follow and can be used to customize the controller to better suit specific applications. Parameter adjustments in the service menu may affect system performance and should be handled with caution.

Service menu usage: As long as the controller is powered on, any user level can access the 505 service menu without shutting down the turbine. The permission to change these parameters is limited to the service user level and above, and requires entering the corresponding password for protection. Login to the service user level is required

Application scenarios

CPC-II (Second Generation Current Pressure Converter) is an electro-hydraulic pressure regulating valve control device designed for positioning the servo mechanism of single acting steam turbine valves. Its extremely high precision and resolution make it very suitable for steam turbine valve control and related turbine speed and load control.

CPC receives a 4-20mA pressure demand signal and precisely controls the oil pressure to accurately locate the single acting steam turbine speed control valve. Accurate and stable steam valve control is directly related to improving the speed and load control of steam turbines, and reducing system mechanical wear.

The redundancy feature of CPC makes it highly suitable for critical steam turbine applications, where the running time and availability of the turbine are crucial. It can be configured to accept redundant pressure demand inputs from one or two (redundant) controllers and track the inputs through voting. Alternatively, CPC can be configured to receive signals from its internal oil pressure sensors and external (redundant) oil pressure sensors, and use the voted health signal.

Its robust design (sturdy actuators, corrosion-resistant materials, single movable rotary valve, and self-cleaning port design) makes it ideal for challenging applications where dirty or contaminated oil may be present.

Optionally, two controllers can be connected to a single CPC in a redundant master/slave manner to allow the turbine to continue operating in the event of any control failure or the need for online changes. For applications that require complete redundancy, two CPCs can be optionally applied in a dual redundancy manner to simplify the entire system and control wiring.

Product description

CPC is an electro-hydraulic pressure regulating valve control device that utilizes a highly accurate internal pressure sensor and PID controller to precisely control steam turbine valves. CPC consists of valve actuator components, pressure sensors, and electronic drive modules. The drive module of the device accepts one (or two) 4-20mA pressure set points and compares these set points with the detected oil pressure to accurately control the turbine valve oil pressure.

CPC controls oil pressure by delivering supply oil to its control oil output port (turbine valve control oil) or returning it to the system supply oil tank. The special PID architecture of this converter enables it to achieve very stable pressure control under normal conditions and respond to the required valve step changes with millisecond level response speed during system or factory transients. As a means of protecting the steam turbine, the internal valve reset spring forces the CPC into a fail safe position (connecting the oil port to the discharge port) and safely closes the turbine control valve in the event of any internal device failure (input power failure, pressure sensor failure, processor failure, etc.).

Main features 

Resistant to oil pollution, precise fluid pressure control, stable and linear valve control, including valve linearization tables, redundant inputs/sensors for critical applications, receiving signals from redundant controllers, redundant (dual) CPC (master/slave) functions, standard installation and hydraulic connections, self-cleaning valve algorithms, status and health indicators, control pressure readings, software service tools with trend analysis, certified for hazardous locations in North America, compliant with applicable EU directives, certified for explosive environments by IECEx, certified for use within the EAC-CU range.

The manual stroke function allows users to manually adjust the CPC output pressure (turbine valve position) locally on the device through the internal manual stroke screw. This local manual stroke function is designed with built-in safety logic to prevent users from accidentally using this function during normal operation. Manual stroke function can also be achieved remotely or locally through CPC’s computer-based PCI tool.

Due to the non-linear flow rate of single-stage and staged inlet steam valves throughout their entire flow range, turbine control is typically detuned to compensate for unstable or sluggish control points throughout the entire range. In order to optimize turbine control, CPC includes an 11 point linearization table that allows turbine original equipment manufacturers or users to compensate for poor valve linearization through digital linearization control and valve flow relationship.

Due to the fact that many steam turbine users utilize redundant pressure converters to improve system reliability, and such applications are prone to sedimentation problems in the equipment, a special “Sill Buster” (patent application pending) program can also be configured to regularly remove internal sedimentation.

Specification parameters

Performance

Accuracy:<± 0.2% of full scale

Repeatability: 0.1% full scale

Temperature drift:<± 0.01% full-scale/° C

Pressure stability:<± 2% set point

Fault safe operation: When power is cut off or a fault is detected, the internal reset spring forces the control port oil to flow towards the discharge port

Configuration: Computer based service tool (RS-232 communication port)

Physical parameters

Size: Refer to the outline drawing, the height x width x depth is approximately (290 x 270 x 270) mm

Weight: Approximately 25kg

Product description

ProTech GII is an overspeed safety device designed to safely shut down steam, gas, and water turbines of all sizes when overspeed or over acceleration events are detected. It accurately monitors the turbine rotor speed and acceleration through active or passive magneto electric sensors (MPUs), and sends shutdown commands to the turbine’s trip valve or corresponding trip system.

According to the system design, ProTech GII has two output types: two dual redundant trip relay outputs using a 2-out-of-3 voting architecture, or three independent non voting trip relay outputs. Its independent alarm relay, 4-20 mA speed reading, and Modbus ®  Communication function makes it easy to integrate into any turbine safety system.

The device comes in embedded models (designed for installation inside a standard 24 inch (610 mm) cabinet front door) and wall mounted models (designed for installation on walls or bases near turbines). When installed inside the casing, it is suitable for harsh environments and has a protection level of IP56 (dustproof, completely preventing water jets similar to giant waves).

To improve reliability, each ProTech GII module (A, B, C) can accept two high voltage power inputs (90-240 Vac/100-150 Vdc) or one high voltage power input (90-240 Vac/100-150 Vdc) and one low voltage power input (18-32 Vdc) depending on the purchased model. This design is based on the principle of high signal selection, allowing the device to operate normally when either or both power sources are available.

Application scenarios

ProTech GII is used to safely shut down steam, gas, and water turbines when turbine overspeed or over acceleration events are detected. Its 12 millisecond response time and speed range of 0.5 to 80000 rpm make it suitable for various types and sizes of turbines.

It can be used in conjunction with turbine control or trip systems, and interfaces with related control systems or factory DCS (distributed control system) through redundant hard wired input and output signals or triple redundant serial Modbus communication ports. An Ethernet gateway can also be selected to easily access the factory Ethernet network.

As a safety device certified by IEC61508 SIL-3 (Safety Integrity Level 3), it can be easily applied to safety systems based on IEC61508 or IEC61511.

Main functions and features

Online testing: Each ProTech GII module can be manually tested through the module front panel, Modbus communication port, or automatically tested through its automatic testing program functionality. Allow users to configure overspeed testing, which is automatically executed on a regular basis, testing each module (A, B, C) one by one, recording each test result, or stopping testing when an error is detected.

Online maintenance: The triple module design allows users to easily replace one of the modules (A, B, C) while the turbine is running normally online. The plug and play structure of the device’s backplane and its module to module learning function improve the convenience of replacement.

Trip, alarm, and overspeed logs: The log function records all trip, alarm, trip valve response times, and overspeed events. The trip log function uses a rolling buffer to record the last 50 detected trip or alarm events and the last 20 overspeed events along with their respective times in memory. Each log file can be viewed from the front panel of the device or downloaded to the computer through the ProTech GII service tool program. Each module uses non-volatile memory to ensure that all recorded events can be saved even in the event of a power outage.

Real time clock: Each ProTech GII module uses a real-time clock to ensure accurate time recording. Special time averaging function is used between modules to ensure clock synchronization.

Acceleration detection: configurable to protect the turbine from high acceleration events. Use the derivative of the velocity signal to detect turbine acceleration and issue relevant trip commands.

MPU detection: The speed sensor input of each module uses a special MPU disconnection detection circuit to verify whether the MPU is correctly connected before the turbine runs, and uses special speed loss detection logic to verify the MPU function during the turbine runs.

Automatic overspeed testing program: It can be configured to periodically perform overspeed testing on each module, and then record and report the test results. Simulate overspeed conditions through an internal frequency generator to complete the test sequence for each module.

Anti sulfur pollution: Using special conformal coating materials, it has excellent long-term protection against H2S and SO2 gases in the 3C2 environment specified in the international standard IEC 721-3-3 1994.

Configuration information

Collocation method

ProTech GII can be configured (programmed) through its front panel keyboard or software service tools running on on-site computers or laptops. For ease of use, all configuration settings, alarm/trip, and overspeed logs can be viewed through the high-resolution 4.2-inch (107 mm) color display screen of each module.

Configure auxiliary functions

The special inter module learning function can reduce configuration time and lower error rates.

Different levels of password security mechanisms are used to protect device configuration settings and restrict access to device testing functions.

Input signal configuration

Power supply

High voltage power supply: 88-264 Vac/47-63 Hz; 90–150 Vdc， Power of 90 W, supporting 2 redundant inputs.

Low voltage power supply: 18-32 Vdc, power 100 W.

Speed signal: 1 channel per module, a total of 3 channels, configurable to receive the following signals

Magnetic electric sensors (MPUs): 100-32000 Hz, 1-35 Vrms.

Proximity probe: 0.5-25000 Hz, 24 Vdc.

Gear teeth range: 1-320 teeth.

Discrete input: Each module has 3 channels, totaling 9 channels, including alarm/trip reset commands, start commands, and speed fault coverage commands.

Output signal configuration

Discrete output relay

Voting relay model: 2-channel total shutdown relay output (2-out-of-3 voting), rated at 8 A @ 220 Vac or 8 A @ 24 Vdc; Each module has 1 alarm relay output, totaling 3 channels, with a rated value of 2 A @ 24 Vdc.

4-20 mA analog output: 1 channel per module, for a total of 3 channels, specifically designed for speedometer readings.

Communication ports: Each module has 1 channel, totaling 3 channels, which are serial RS-232, RS-422, RS-485 Modbus ports.

Other configuration related information

The installation size (including panel) is approximately 330 x 445 x 159 mm (13 x 17.5 x 6.25 inches).

According to the ordered part number, it is designed to be wall mounted or base mounted, or vertically embedded in panels or cabinets.

The protection level is IP56.

The working/storage temperature range is -20 to+60 ° C.

Application scenarios

SPM-D10 is a microprocessor based synchronizer suitable for three-phase AC generators equipped with Woodward or other compatible speed controllers and automatic voltage regulators. It achieves automatic frequency, phase, and voltage matching through analog or discrete output bias signals, and the model 8440-1668 SPM-D1040B/XN can directly replace the SPM-A synchronizer.

Main functions and features

Synchronization function

Capable of phase matching, slip frequency synchronization, and voltage matching.

Perform two-phase detection on the generator and busbar.

There are selectable operating modes, such as SPM-A (Run, Check, Allow, and Close).

Can perform synchronous checks and synchronous time monitoring.

Isolation operation: capable of frequency control and voltage control.

Dead bus operation: Circuit breakers can be closed as needed.

Control output

Standard configuration: There are discrete up/down outputs for speed and discrete up/down outputs for voltage.

X and XN packages: Voltage and speed analog bias outputs can be freely configured for all levels (various configurations such as ± 1V, ± 3V, 0 to 5V, 0.5 to 4.5V, ± 10V, ± 5V, 0 to 20mA, ± 20mA, etc.); The speed bias output can be configured as a 500Hz PWM output and an adjustable voltage level; Two up/down outputs can be configured as speed or voltage outputs.

Operational Characteristics

Two row LCD display screen is used for operation and alarm indication, with synchronous oscilloscope function, which can indicate control activities and circuit breaker status.

Equipped with multi-level password parameter protection function, it can be configured directly or through a PC, and the language can be adjusted between English or German.

Specification parameters

Accuracy: Level 1.

power supply

Standard: 24 Vdc (± 25%).

N and XN packaging: 90 to 250 Vac/dc.

Inherent power consumption: maximum 10W.

environmental condition

Environmental temperature: -20 to 70 ° C; N and XN packages are -20 to 60 ° C.

Environmental humidity: 95%, non condensing.

Voltage parameters

Rated/Δ voltage: [1] 66/115 Vac or [4] 230/400 Vac; Maximum value (V max): [1] 150 Vac or [4] 300 Vac; Rated phase to ground voltage: [1] 150 Vac or [4] 300 Vac; Rated surge voltage: [1] 2.5 kV or [4] 4.0 kV.

Measurement frequency: 40 to 70Hz; linear measurement range up to 1.3 times rated voltage; Input resistance: [1] 0.21 M Ω, [4] 0.696 M Ω; maximum power consumption per path:<0.15W.

Discrete input: With isolation function, the maximum input range is 250 Vac or DC, and the input resistance is about 68 k Ω.

Relay

Equipped with isolation function, the contact material is AgCdO.

Load (GP): 2.00 Aac@250  Vac、2.00  Adc@24  Vdc、0.36  Adc@125  Vdc、0.18  Adc@250  Vdc。

Guided load (PD): 1.00 Adc@24  Vdc、0.22  Adc@125  Vdc、0.10  Adc@250  Vdc。

Shell and connection

Shell type: APRANORM DIN 43700.

Size: 144 × 72 × 122 mm; Front panel cut: 138 [+1.0] × 67 [+0.7] mm.

Connection: Depending on the connector, it can be a screw/plug terminal, 1.5 mm ² or 2.5 mm ².

Application scenarios

SPM-D11 is a microprocessor based synchronizer suitable for single-phase or three-phase AC generators equipped with Woodward or other compatible speed controllers and automatic voltage regulators. It achieves automatic frequency, phase, and voltage matching through analog or discrete output bias signals, combined with synchronous, load and power factor control or synchronous load sharing of a circuit breaker, as well as generator protection functions.

Main functions and features

Synchronization function

Capable of phase matching, slip frequency synchronization, and voltage matching.

Perform two-phase detection on the generator and busbar.

There are selectable operating modes, such as SPM-A (Run, Check, Allow, and Close).

Can perform synchronous checks and synchronous time monitoring.

Load/reactive power sharing

It can perform parallel operation of the power grid, active power control, and true effective value power calculation. The active power setting value of the generator can be set through parameters (2 values) or 0/4 to 20mA.

Support soft uninstallation and power factor control, with the power factor setting value set through parameter settings.

There are power limit values and relay outputs.

Isolation operation

Can perform frequency control and voltage control.

Dead bus operation

Circuit breakers can be closed according to demand.

Protection function

Perform single-phase current transformer detection and two-phase voltage detection on the generator.

Equipped with generator overvoltage/undervoltage, overclocking/underfrequency, reverse/reduced power (32R/F), and overload protection functions.

Control output

The voltage and speed analog bias output of LSXR package can be freely configured for all levels (various configurations such as ± 1V, ± 3V, 0 to 5V, 0.5 to 4.5V, ± 10V, ± 5V, 0 to 20mA, ± 20mA, etc.).

The speed bias output can be configured as a 500Hz PWM output and adjustable voltage level.

Two up/down outputs can be configured as speed or voltage outputs.

Operational Characteristics

Two row LCD display screen is used for operation and alarm indication, with synchronous oscilloscope function, which can indicate control activities and circuit breaker status.

Equipped with multi-level password parameter protection function, it can be configured directly or through a PC, and the language can be adjusted between English or German.

Specification parameters

environmental condition

Environmental temperature: -20 to 70 ° C.

Environmental humidity: 95%, non condensing.

Electrical parameters

Rated/Δ voltage: [1] 66/115 Vac or [4] 230/400 Vac; Maximum value (V max): [1] 150 Vac or [4] 300 Vac; Rated phase to ground voltage: [1] 150 Vac or [4] 300 Vac; Rated surge voltage: [1] 2.5 kV or [4] 4.0 kV.

Measurement frequency: 40 to 70Hz; linear measurement range up to 1.3 times rated voltage; Input resistance: [1] 0.21 M Ω, [4] 0.696 M Ω; maximum power consumption per path:<0.15W.

Rated current (I rated): [1]../1A, [5]../5A; Linear measurement range up to 3.0 times rated current; Load:<0.15 VA; Rated short-time current (1s): [1] 50 × I rated, [5] 10 × I rated, with isolation function.

Input range: 12/24VDC or 18 to 250 Vac/dc; Input resistance: approximately 6.8 k Ω or 68 k Ω.

Relay

Equipped with isolation function, the contact material is AgCdO.

Load (GP): 2.00 Aac@250  Vac、2.00  Adc@24  Vdc、0.36  Adc@125  Vdc、0.18  Adc@250  Vdc。

Guided load (PD): 1.00 Adc@24  Vdc、0.22  Adc@125  Vdc、0.10  Adc@25

Overview

Introduction: This manual (04042C) provides overall instructions, installation, operation, adjustment, operating principles, troubleshooting, and replacement of spare parts for Woodward TG-13 and TG-17 governors.

Describe

TG-13 and TG-17 are mechanical hydraulic differential governors used to control steam turbines that do not require synchronous (constant speed) operation.

The maximum rotation angle of the output shaft of the governor is 40 °, and the recommended angular travel from no-load to full load is 2/3 of the governor’s full travel.

The maximum working capacity of TG-13 is 12.2 foot pounds, and TG-17 is 17.5 foot pounds (at 40 ° full stroke of the governor).

The internal gear pump has different size specifications, suitable for different standard speed ranges such as 1100 to 2400 rpm, 2400 to 4000 rpm, 4000 to 6000 rpm, etc.

During operation, the internal oil pressure of TG-13 is 1034kPa (150psi), while the oil pressure of TG-17 is 1379kPa (200psi).

The governor housing comes in two types: cast iron and cast aluminum. There is a speed difference type, and the internal adjustment setting has a difference rate before leaving the factory. The speed adjustment methods include screw type (standard configuration) and lever type (optional configuration).

The rotation direction of the drive shaft is unidirectional and can be changed on site. The cast iron casing needs to be adjusted internally, while the cast aluminum casing can be adjusted externally (by removing 4 bolts and rotating the pump body 180 °).

Simple maintenance, few coupling parts, fully enclosed design, internal circulation of pressure oil, oil level indicator mounting holes on both ends of the shell, easy to check the oil level.

Install

Introduction: When handling and installing, be careful to avoid hitting the transmission shaft, output shaft, speed setting shaft or speed control screw, to prevent damage to the seal, internal parts and factory settings. Do not use the speed control transmission shaft as a support to place the speed control.

Reception: The speed controller is fixed on a wooden base with bolts when shipped from the factory, vertically placed and packed in a packaging box. There are oil level indicators on both sides of the shell, and the oil filling cover is installed in a vertical installation and operation position. After factory testing and calibration, the rear seat is empty, sealed and painted. There is a small amount of oil film on the surface of the internal parts to prevent rust, and the exposed shaft is sprayed with rust proof oil. There is no need to clean or rinse the interior before installation, operation or retesting.

Storage: It can be stored directly in the short term. In harsh environments or long-term storage, it is necessary to refuel and follow the packaging instructions in Woodward manual 25075 “Packaging for Commercial Storage of Mechanical Hydraulic Controllers”. If the oil cap is in a horizontal running position and needs to be placed vertically, the oil cap and screw plug should be removed and replaced before oil injection to prevent leakage.

Drive shaft rotation direction

Looking down from the top of the governor, define the direction of rotation of the drive shaft, and mark the nameplate with “CW” (clockwise) or “CCW” (counterclockwise).

The transmission shaft has only one rotation direction, and the rotation direction viewed from the top should be the same as the rotation direction of the engine transmission shaft viewed from the mounting seat downwards. Otherwise, the oil pump cannot establish oil pressure, resulting in component heating and rotating component jamming.

Change the rotation direction of the transmission shaft

Governor with eccentric gear pump not on the lower body: Remove the governor and drain the oil, place it flat with the cooling joint facing up, rotate the transmission shaft so that the keyway is facing up, loosen the 4 pump body bolts, remove the pump body, rotate the eccentric ring so that the pin hole is close to the desired direction arrow, insert the pin, install the inner and outer gears, install the pump body on the transmission shaft and tighten it, confirm that the transmission shaft rotates flexibly, install the sleeve stop ring and leave the gap.

Gear pump eccentric speed regulator on the lower body: Remove the 4 bolts of the pump body, rotate the pump body 180 °, align the pump body arrow with the reference point of the housing. If it is screw speed regulation, screw in the speed screw clockwise. If it is lever speed regulation, turn the speed setting shaft to the maximum fuel position and hold it. Install the bolts and confirm that the transmission shaft rotates flexibly. Remove the upper cover to confirm that the sleeve rotates with the transmission shaft.

Governor installation

It can be installed horizontally or vertically. The oil cap and drain plug are installed in the factory in the vertical running position. If installed horizontally, they need to be moved to the corresponding position to ensure that the power piston is completely immersed in oil, and the oil level indicator also needs to be moved to the correct position.

Ensure sufficient space for installing connecting rods and performing oil maintenance, confirm correct rotation direction and speed range, correctly position the drive shaft and connect it to the turbine

Application scenarios

The 505E controller is designed for single extraction and/or inlet steam turbines of various sizes and applications, and can start, stop, control, and protect single extraction and/or inlet steam turbines or turbine expanders that drive generators, compressors, pumps, or industrial fans. Its unique PID structure is suitable for controlling steam equipment parameters, such as turbine speed, load, inlet pressure, exhaust manifold pressure, extraction or inlet manifold pressure, or tie line power. The controller achieves stable control during normal operation of the steam turbine through special PID to PID logic, and switches to disturbance free control mode in case of equipment abnormalities, reducing process overshoot or undertuning.

Product description

Hardware and appearance

Adopting industrial grade reinforced casing, it can be installed in the system control panel of the factory control room or next to the turbine.

The front panel combines programming station and operator control panel (OCP) functions, with a user-friendly interface that facilitates engineers to program according to specific factory requirements. Operators can easily start and stop the turbine and enable/disable any control mode, with password security protection program mode settings. The two-line display screen of the equipment allows the operator to view the actual and set values on the same screen, simplifying the operation of the turbine.

The input and output wiring of the turbine interface is located on the lower back panel of the controller, and the pluggable terminal block is convenient for system installation, troubleshooting, and replacement.

Core features: on-site configurability, integrated operator control panel, integrated first issue indicator logic, user-friendly menu format, online (standalone) configuration changes, large LED display screen Modbus ®  Communication function, integrated valve decoupling and protection calculation logic, multiple decoupling modes, and the use of sulfur resistant conformal coating.

Cost benefit design

The 505E controller integrates turbine control, system sequence controller, operator control panel, and first output indicator functions, reducing external system equipment and system installation, wiring, and troubleshooting work. This controller can be configured on site, and professional factory personnel can make major functional changes on site. Minor functional changes can be made online when process changes require it. Its first indicator logic can indicate internal and external system related alarm and shutdown situations, greatly simplifying and reducing system troubleshooting work.

Communication function

The 505E controller can be controlled through two Modbus protocols ®  The communication ports directly communicate with the factory distributed control system and/or CRT based operator control panel, and these ports support RS-232, RS-422, and RS-485 communication using ASCII or RTU Modbus protocols. It can also communicate with the factory DCS through a hard wired connection, and all 505E PID settings can be controlled through analog input signals without sacrificing interface resolution and control performance.

System protection

It has functions such as integrated overspeed protection logic, first out indication (10 independent shutdown inputs), turbine operating range limiter, disturbance free switching between control modes when sensor faults are detected, local/remote control priority and selection, and fail safe shutdown logic.

Control function 

Available PID controllers: speed/load PID (with dual dynamic characteristics), extraction/intake PID, auxiliary PID (limiter or controller), cascade PID (manifold pressure or tie line control).

Control capability: including speed/frequency control, extraction/inlet manifold pressure control, turbine or generator load control or limitation, turbine inlet manifold pressure control or limitation, turbine exhaust manifold pressure control or limitation, factory inlet and outlet power control or limitation, synchronous load distribution between units (with DSLC) ™ Control, etc.

Main features: critical speed avoidance (3 speed bands), automatic start program (hot start and cold start), valve limiter, safety protection (password protected program), dual speed/load dynamic characteristics, first out indication (shutdown), zero speed detection through proximity probe (<0.5Hz), overspeed trip peak speed indication, two programmable function keys on the 505E front panel, two independent Modbus communication links, remote simulation settings for speed/load, extraction/admission, auxiliary and cascade, program upload/download function, compressor feedforward decoupling algorithm, etc.

Control Specifications

Input

Power supply: Supports multiple power inputs, including 18-32 Vdc、90–150 Vdc、88–132 Vac（47–63 Hz）、180–264 Vac（47–63 Hz）

Speed: 2 magneto electric sensors (MPUs), input range 1-30 Vrms; Or proximity probe (providing 24 Vdc power supply), frequency range 0.5 to 15 kHz

Discrete inputs: There are a total of 16 contact inputs, of which 4 are dedicated inputs and 12 are programmable inputs

Analog inputs: 6 programmable current inputs, with an input range of 4-20 mA

Output

Valve/actuator driver: 2 actuator outputs with an output range of 4-20 mA or 20-160 mA

Discrete output: 8 relay outputs, of which 2 are dedicated outputs and 6 are programmable outputs

Analog output: 6 programmable current outputs, with an output range of 4-20 mA

Application and Overview

The Woodward 723 generator controller is suitable for various generator application scenarios, including auxiliary generators and diesel electric propulsion in ship systems, as well as islanding mode operation and basic load operation on infinite power grids in power plant systems. It has closed-loop speed control function, equipped with torsion filter and notch (band stop) filter, which can alleviate low-frequency oscillation problems caused by engine, generator inertia and flexible coupling. The controller has three operating modes, namely droop control based on 4-20mA megawatt sensor input or actuator position, synchronous load distribution with soft loading/unloading and automatic generator circuit breaker opening command after engine unloading, and megawatt control with soft loading/unloading and automatic generator circuit breaker opening command after engine unloading.

Hardware specifications

Model and output: The models include 8280-500, 8280-501, 8280-502, and 8280-503, which correspond to different voltages and output types. For example, 8280-500 is a high-voltage control with an actuator output of 0-200mA.

Power supply and power consumption: The power supply has 18-40Vdc (nominal 24 or 32Vdc) and 90-150Vdc (nominal 125Vdc), with a nominal power consumption of 40W.

input/output

Speed signal input: The frequency range of the magneto electric sensor is 400-15000Hz, and the proximity switch is 7.5-1000Hz.

Digital input: 8, 8mA at 24Vdc.

Analog inputs: 4, 4-20mA or 1-5VDC.

Analog output: 3, of which 2 are 4-20mA or 0-1mA (connected to instruments or computers), and 1 is 20-160mA or 4-20mA.

Output of actuator: 1, 20-160mA or 4-20mA.

Communication port: The communication port (J1) of the programmer is RS-422, 9-pin D-type connector, 1200 baud rate, full duplex; The communication ports (J2 and J3) are RS-232, RS-422 or RS-485, 9-pin D-type connector, 1200-38400 baud rate, full duplex.

Environmental parameters: working environment temperature -40 to+70 ° C (-40 to+158 ° F), storage temperature -55 to+105 ° C (-67 to+221 ° F), humidity at 38 ° C is 95%, anti electromagnetic interference/radio frequency interference complies with MIL-STD 461C (Parts 5 and 9) in the United States, humidity complies with MIL-STD 810D Method 507.2 Procedure III in the United States, mechanical vibration is a swept sine wave of 24-2000 Hz, constant acceleration of 2.5 Gs, resonance retention -1 million cycles, total time per axis is 3/4-6 hours, mechanical impact complies with MIL-STD 810C Method 526.2 Procedure I (basic design testing), Procedure II (transport drop testing, packaging) in the United States. Program V (Workbench Operation), salt spray complies with ASTM B 117-73.

Key points of installation

Unpacking and Inspection: Before installation, it is necessary to read the relevant content on electrostatic discharge protection. When unpacking, handle the electronic controller carefully and check for any damage. If there is any damage, immediately notify the shipper.

Power requirements: The high-voltage version requires a 90-150Vdc voltage source, and the low-voltage version requires an 18-40Vdc voltage source. Both have a maximum power consumption of 40W and should not exceed the input voltage range. If battery power is used, an AC generator or other battery charging equipment should be equipped.

Location selection: The installation location should consider ventilation, maintenance space, moisture resistance, distance from electromagnetic interference sources, and avoidance of vibration. The working temperature range is -40 to+70 ° C (-40 to+158 ° F), and it cannot be installed on the engine.

Electrical connection: All shielded cables must be twisted pair, and do not attempt to tin plated braided shielding layers. All signal lines should be shielded, and the shielding layer should be connected to the nearest chassis ground. The exposed length of wires outside the shielding layer should be as short as possible, not exceeding 50mm (2 inches). The other end of the shielding layer must be open and insulated from any other conductor. Do not lay the shielded signal line together with other wires carrying high currents.

System function

Engine speed related functions

Speed sensing: The controller has two speed sensing inputs, which can be configured as torsional filtering (to make operation smoother, suitable for flexible couplings) or high signal selection (to achieve speed sensing redundancy, enabled when one signal fails). If a torsion filter is used, the speed sensors should be located on both sides of the coupling; If high signal selection is used, the two speed sensing devices should be located on the same speed measuring disc. Speed sensor # 2 can also be configured to detect the speed of the turbocharger.

Speed filtering: Each speed sensor input has a low-pass filter that can filter out unwanted frequencies on the speed sensor. If tuned above 15.9Hz, the filter will be automatically disabled. In addition, a notch filter can be enabled, and its filtering frequency should be set to the resonance frequency of the velocity signal that needs to be filtered. The filtering Q factor can adjust the attenuation degree of the signal frequency filtered by the band stop filter.

Speed control: including idle speed, rated speed settings, overspeed trip function (starting and stopping when the set speed is reached to prevent overspeed), as well as minimum and maximum speed reference limits and acceleration/deceleration rate control.

Synchronization and load control function

Engine start: When the Run/Stop contact is closed (or configured to be open), the speed reference is at idle. When the engine speed exceeds the idle/rated switching speed, the speed reference will ramp up and down at an acceleration/deceleration rate to the rated speed, which can be interrupted by temporarily closing the deceleration contact. If the idle/rated selection function is enabled, after the engine is started, the idle or ramp to rated speed is determined based on the contact position.

Synchronization function: When the engine reaches the rated speed and maintains the synchronization readiness delay time within the synchronization readiness limit, the “ready synchronization” state is achieved through Modbus ®  Convey as True. The speed reference can be adjusted by inputting or adding or subtracting contacts through the unit synchronizer to achieve synchronization with the busbar. Alternatively, after the auxiliary contacts of the generator circuit breaker are closed, the bias speed reference can be input through the system synchronizer to achieve cross busbar connection or synchronization with the grid.

Droop control: When the synchronous/droop contacts are open and the auxiliary contacts of the generator circuit breaker are closed, the following droop modes operate. Calculate the speed droop value based on the droop percentage and engine load. The engine load comes from the input of the megawatt sensor. If the signal fails, it is determined based on the output position of the actuator. At the same time, provide a “droop pulse” function to prevent the engine from sinking into reverse power when connected to the bus in droop mode.

Synchronous load distribution: When the synchronous/droop contacts are closed, and the auxiliary contacts of the generator circuit breaker are closed and the load input signal is normal, synchronous load distribution is enabled. The first online machine immediately closes the relay K4 contact on its load sharing circuit. The subsequently selected synchronous units will adjust the load according to the automatic loading/unloading rate until the load shared with the synchronized units is within the specified load sharing error range. At this point, relay K4 closes to connect to the load sharing circuit and achieve load balancing. It also has an automatic soft unloading function. When the unloading contact is closed (instantaneously), the engine load decreases at an automatic unloading rate to the unloading trip level, and then a command to open the generator circuit breaker is issued.

Megawatt control: When the auxiliary contacts, grid contacts (if used), and megawatt control contacts of the generator circuit breaker are closed and the megawatt load input is not disabled, operate in megawatt control mode. The megawatt reference value can be adjusted by adding or removing contacts, or based on internal megawatt reference or remote reference (4-20mA or Modbus) ®） Adjustment. If the remote reference input fails, the megawatt reference will lock the last healthy value.

Protection and restriction functions

High/Low Frequency Protection: In megawatt control mode, it can be configured to open the grid and/or generator circuit breakers or switch to droop mode (megawatt coverage function) when the grid frequency is too high or too low.

Limiting functions: including start-up and maximum fuel limiter (limiting excessive fuel supply or flooding during engine start-up), engine shutdown limiter, frequency load limiter (limiting engine load when grid frequency exceeds preset limits during megawatt control), boost air pressure limiter (providing fuel limitation based on 4-20mA boost air pressure input signal), etc.

Load rejection function: When the generator circuit breaker or grid circuit breaker is opened and the load is above a certain level, the load rejection algorithm takes effect, driving the actuator output to zero for a period of time to reduce speed overshoot.